Construction System

ABSTRACT

A building construction system utilizing prefabricated stacked modules creating tubular resistant modules forming spaced hollow columns interconnected by bridges and a plurality of elongate structural profiles made of bendable steel used as column and beam components in the modules.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to construction systems and, more particularly, to construction systems composed of high-strength, cold-rolled, laminated, metal building elements, sometimes referred to herein as profiles, and forming stackable modules coupled with the profiles.

Brief Discussion of the Related Art

The construction industry is vital for progress in any country. Especially for countries which are in their development phase. Among the most relevant factors towards which this industry's efforts must be directed are housing and the provision of physical infrastructure in schools, hospitals and hotels. In order to promote the construction industry, each country has implemented various measures, from the advantages given to national investors in the sector, to the massive import of foreign capital invested in construction including, naturally, the country's own subsidy through specialized institutions intended for that purpose. Nevertheless, rarely is the possibility of an improvement found in construction systems allowing for a net reduction in costs which, in turn, brings about a lower price for the finished product.

New techniques have been developed in the construction industry, tending towards a reduction in construction costs and in the time normally needed to build. One of the most important of these techniques is prefabrication. In this connection, two main systems have emerged: the panel system and the module system. Units built from prefabricated elements/components obtain the maximum results with the minimum cost whenever both the design and the construction themselves are inspired by principles such as structural strength and security with a minimum of maintenance, easy construction and installation of the elements without the need for sophisticated equipment or costly installation, which tend to make the manufacturing of elements less easy, relatively simple installation of the finishes and other elements in addition to the prefabricated elements, the most advanced preparation possible of the components, before being hoisted up for installation, the layout and connections of the components to the structural unit must be flexible and coupled to the minimum of secondary structural systems, the final result of the constructed unit must be comfortable, safe and architecturally flexible. Any construction system based on prefabrication must bring together the characteristics pointed out above.

A panel system typically consists of sheets or panels manufactured in a plant, transported to the site where the building is going to take place and then assembled to form a structural unit. The panels, whether they be bearing or partition walls, are, typically, thermal and acoustic. The panels are prefabricated in molds, in either a horizontal or vertical position. Their production is straightforward and economical. The panels can be made to any size or thickness, depending on the assembly system. The panels are reinforced with two layers of metal mesh, welded and strengthened with metal bars where necessary. The places for the doors, windows and utilities such as the lighting and the electric current through ducts, are added in the molds. The normal manufacturing cycle of a panel is twenty-four hours. When it has been manufactured, it is transported by special means to the building site. The next phase is more difficult, as it requires more time and a good measure of skill on the part of the workers installing the panels, especially in relation to the safety and quality of the construction, given the relatively large number of panels to be aligned and fixed. Any human error during these operations can jeopardize the erection of the building. This is one of the biggest disadvantages of the panel system. Furthermore, the connections between the vertical panels are relatively weak, and the bearing walls must be sufficiently hardened to avoid a concentration of the load and undesirable bending or torsion. The structural pattern of the panel system reduces and limits flexibility, from both the structural and architectural points of view, resulting in monotonous buildings. Working on finished elements ‘in situ’ is costly and does not differ much from conventional construction methods. Accordingly, the reduction in costs achieved in the first phase of panel production is largely lost in the installation phase. Moreover, the panel system requires strict project management to be able to guarantee its stability when faced with seismic movements, since the design of the joints requires a very careful construction process in order to maximize their strength.

A module system typically employs prefabricated modules which can be classified as the following types: module type I wherein the floors and walls of each module are cast simultaneously, with the roof slab being built and cast afterwards; module type II wherein the bottom or floor of the module is manufactured first and the sides and roof of the module in a second step—in other words, a reverse procedure to that of module type I; module type II wherein the module is manufactured in two pieces similar to those of module type I, both pieces are laid on one of their sides and are joined in the middle, thereby forming a complete module with a roof and floor; and module type IV wherein the walls, roof and floor are made in one step and, sometimes, parts of the front or back walls, or both, are eliminated to accommodate doors and windows.

For type I and type IV modules, steel reinforcement of the prefabricated bottom is put in the formwork in one piece. The reinforcement of the panels is also made up of one single piece with the dimensions of the respective walls and is fitted separately for each one of them. Meshes used to make the reinforcements overlap in the corners and are fixed by welding. As a rule, electrically-welded mesh is used, strengthened with bars where necessary, so as to make significant savings in the preparation time for casting.

For type II and type III modules, which have no bottom, the internal mold has fixed dimensions with a sliding base. This arrangement allows for the slab and wall steel reinforcement to be prefabricated in one single piece. The frames for the doors and windows are fixed to the interior mold and steel bolts, pipes and other accessories that have to be embedded in the walls or floors are fixed to the steel reinforcement. The exterior formwork is then put in place for subsequent casting.

For type I and type IV modules, the bottom slab is cast first. When the concrete has set sufficiently, the walls are cast from above. In this case, it is necessary for the concrete of the base to become hard enough to take the wall formwork. This involves the risk that ‘cold’ joints will appear, meaning that the new concrete does not adhere perfectly to the old.

For these types of modules, steam curing is recommended for the purpose of optimum performance in the use of the molds. Thus, each module can be practically finished at ground level, with its finished elements, which may include utilities, installations, interior partitions, insulating systems, windows, doors, floors, etc. so that on site it is only necessary to connect the pipes to the main utility systems.

There are disadvantages to each of these systems, depending on the characteristics of the building, the availability of materials and manpower and the requirements of the construction process. For instance, within the systems that are classified as type 11, which include the ‘Shelley System’, that has certain characteristics of type IV modules. As shown in U.S. Pat. Nos. 3,503,170 and 3,643,390 to Shelley, the Shelley system includes the alternated stacking of the modules, to make usable spaces between them (in the shape of a chessboard).

Besides these four types, there are a variety of construction systems which do not fit definitively into one of the four types classified here, but which basically comply with several of the general principles mentioned. One of them is system ‘K’, the basic element of which is a reinforced concrete semi-module or frame, in other words a module with no top or bottom, which forms an independent unit, prefabricated separately from the subfloor slabs. The semi-modules are stacked vertically and separated by continuous subfloor slabs. The stack of semi-modules forms a body of columns which serves as a support for the continuous subfloor slabs. The horizontal roof and floor joints between the semi-modules and continuous floors are separated by a Neoprene sheet of 3 to 6 millimeters in thickness. After the semi-modules are erected, post-tension is applied vertically along all their walls and horizontally in one or two directions of the slabs which form the subfloor. The main advantage of this system is the lighter weight of the module, allowing for the use of more lightweight equipment. However, by eliminating the top and bottom of the module, the advantage of putting the utilities under the floor is lost, as they remain within the space of the semi-module. Also, the floor cannot be finished. Furthermore, the maximum limit for the separation between the bodies of columns formed by the stacking of the semi-modules is reduced to 4.5 meters, owing to the use of solid slabs for the continuous floors. Having no top or bottom, the semi-modules are deformable and lose the advantage of complete modules, from the structural and handling point of view, as regards rigidity and strength.

SUMMARY OF THE INVENTION

The construction system of the present invention has the advantages of flexibility, simple assembly, simple transport, finishing and final touches at the plant, not requiring heavy equipment for assembly and not requiring specified labor for connections while overcoming the disadvantages of the prior art described above.

The construction system of the present invention can be considered to be a building system, or construction system for a building, composed basically of three interconnected components. The system provides an architectural solution based on a typology, which means that with the same elements one can build many types efficiently and can adapt to any economical program from low income to middle and luxury housing types. The system allows cultural adaptation to particular family types and also to different environment situations, climate, topography, geology, etc.

The construction system of the present invention is an engineering structural solution that responds to architectural concepts, producing a building composed of three dimensional modules piled one on top of the other and connected to form a “tubular resistance module” or “hollow column” with enormous inertia and resistance to earthquakes and winds with a bridge or slab and a roof connecting each hollow column. This connection is flexible in order to dissipate horizontal and vertical movement. Connection horizontally with a plurality of columns forms a unit of both strength and flexibility. The modules are independent of circulation so each can be specially organized with great adaptability to orientation views, site, wind, etc.

The construction system utilizes structural profiles made of high performance steel, which can include laminated, that is bent in general shapes, but include a central web and spaced inner side flanges. “Ribs” are formed in the web and/or inner flanges in the bonding process, depending on the function of the profile. The profiles can have a “closed” shape with the ribs appropriately located. The profile structural elements used as columns and other elements weigh two-thirds of prior art profiles with the same resistance. The design process of the construction system includes the adaptation of the system to programmatic economic and cultural factors (cost estimate and size as well as space organization). As well as urban design, environmental and climatic considerations, the elements define a site plan and the size and type of typology to be used.

The construction system of the present invention is a structural design which responds to a particular architectural solution as well as environmental forces such as earthquakes, winds, and the like. The structural design can result in a construction kit which includes all the building elements: foundation plates, vertical profiles (columns) and horizontal beams and roof as well as connectors between them. The kit can be preassembled in a factory where profiles are rolled, pinched and welded together forming rigid frames that can be easily transported to a building site.

Erection takes place by placing frames on top of each other, sliding the columns through the connectors and raising them with pulleys, and bolting them in place. The erection process can be completed in two days for a five story building. Slabs and roof are placed last in the material shape and form best suited for the specific site.

The construction system of the present invention has characteristics devised to construct buildings which are flexible, versatile, adaptable to different topographies, easy and quick to install and economical. Where the building is a dwelling, the construction system of the present invention creates relatively invariable inflexible spaces, such as staircases, bathrooms and kitchens (spaces with damp elements), variable or flexible spaces, such as bedrooms, lounges, dining rooms and terraces, concentration of inflexible spaces which are referred to herein as “boxes”, layout of the boxes in parallel groups, spacing between the groups of boxes to form a ‘bridge’ in which the flexible spaces are arranged and concentration of the above elements such as concentration of the damp elements (kitchen and bathrooms). The ‘boxes’ for the utilities are located at the extremities of the flexible area.

External walls are adaptable to plans (functional structure) such that the dwellings are easily adaptable to various finishes and types of walls and offer, with their versatility, multiple possibilities for application in different localities.

The construction system of the present invention breaks with the traditions of low-rise constructions and is easily adjustable to any type of geographical conditions, whether they concern the climate, topography or irregular terrain. By its own characteristics, each building functions structurally in an individual way, its floor plan can be laid out using any model established by design and urban planning.

In one aspect of the construction system of the present invention, a metal framework forms boxes, used together with a system of panels which can be, but need not be, prefabricated. Each box forms part of a specific unit of a dwelling. The boxes are stacked vertically and form a resistant tubular module. Horizontal structural elements (hollow-core girders and slabs) are inserted into the resistant tubular module like a bridge to form a large frame.

For a single-family dwelling, the building has, as a main concept, the adaptation of the spaces and areas of the dwelling to user requirements under the following characteristics: concentration of the utilities (damp elements); finishes and partition walls adaptable to different localities; and adaptability to terrains with different topographies. Concentration of the building elements are as follows: concentration of the damp elements (kitchen and bathrooms); the boxes for the utilities are located at the extremities of the flexible area: and thus various arrangements for grouping.

For a multi-family dwelling, the buildings are structured around resistant vertical elements (i.e. resistant tubular modules forming large, spaced, hollow columns) where the elements of limited flexibility are arranged as follows: damp elements (bathrooms, kitchen and laundry) and horizontal elements (bridge), and the spaces of maximum flexibility accommodate living areas (lounge, dining room) and bedrooms. The buildings have cross ventilation and can be connected by stairways at half-levels, eliminating corridors and allowing for adaptation to uneven terrain. Minimum horizontal and vertical circulation is achieved via a module intended for this purpose giving access to the apartment units.

The construction system of the present invention uses structural modules with a metal framework that can feature an open (bottom or top) horizontal box, for the purpose of being stacked vertically, used in conjunction with a system of panels in normal and/or hollow-core reinforced concrete, metal, resins or combinations thereof. The joints are fixed by bolts or welding, and the slabs forming the bottom or top can be solid or ribbed. They can have areas filled with lightweight material, so that the utilities can be embedded in them, maintaining minimum weight. The resistant tubular modules bear the horizontal and vertical load requirements of the building. Other elements, such as brackets, bolts and the like, serve to support or join other horizontal structural elements, such as hollow-core girders and slabs, which connect the resistant tubular modules like a bridge, to form a large frame which offers greater resistance to seismic pressures. The construction system can be used in conjunction with panels, if desired, whether in normal or hollow-core reinforced concrete, metal, resins or a combination thereof. Each module forms part of a specific unit of the dwelling. The final touches, finishing and utilities can be incorporated before the modules are erected on the same production line. The resistant tubular modules can be laid out on a floor plan according to any model drawn up in the design: linear, bi-linear or radial, among others. The construction system allows for the design of a module which, because of its laminar structure, can be moved from the vertical stack in the direction of its greatest dimension, thereby obtaining a building which is staggered on one side and flies on the other. The modules can be prefabricated in a factory or elsewhere or be put together on an ongoing basis.

In the construction system of the present invention, prefabricated modules are stacked vertically, forming a resistant tubular module, which supports horizontal and/or vertical structural elements, such as girders, slabs and secondary screens. The elements are held together by joints, which may have inserted Neoprene membranes, mortar or other similar materials. The joints are fixed with bolts, welding or post-tension vertical and horizontal bars. The slabs which form the bottom or top of the module are prefabricated to fit onto it and can be solid or ribbed. For high buildings, where horizontal pressures originating from dynamic forces (earthquakes and winds) are a major problem, a post-tension system is designed in sections in order to guarantee overall stability during and after the construction. The stresses of horizontal cuts are resisted by the effect of friction, steel bolts, reinforced concrete shear keys or a system using these elements partially or totally.

The modules can be made of a screen element or a flexible frame. In each case, the walls of the module act as uprights for rigidity and/or columns, which provide overall rigidity and contain the ducts for fitting the post-tension bars, which eliminate the traction stresses of the resistant tubular modules in buildings of more than six floors. Joints can be designed to bear the reversal of stresses, by way of welding or bolts, of the stresses which arrive at these joints. The tensions resulting from off-centering brought about by these movements and horizontal dynamic pressures are borne by vertical and/or inclined cables which are fitted in the walls and columns of the modules. The module containing utilities such as bathrooms and kitchen already has these utilities incorporated into the module before being erected.

The construction system of the present invention uses metal elements along with composite panels with a lightweight core. The metal elements are elongate steel structural profiles. They can be used to put together the linear-type elements (columns and beams/girders) to form three-dimensional pieces (modules), characterized by a skeleton structure combined with vertical and horizontal composite panels. The profiles are cold-laminated from structural steel and then assembled in girders and columns, following various forms of coupling, in order to optimize the structural design. A profile can be fixed using the web or the flanges. With the profiles and their combinations, the following is obtained: a factory-built element of great precision and rapid production, more efficient and economical use of steel, an efficient cost-weight ratio, combinatory flexibility, optimizing structure-architecture requirements; and assembly with bolts, minimizing welding on site. Other metal elements can include soft plates, tie bolts, connection nodes, connection bolts, and reinforcement plates.

The composite panel elements, slabs, partitions and walls, can be modular panels made up of two electro-welded galvanized-steel meshes, joined together by way of connectors, with a sheet of appropriately-molded expanded polystyrene inserted. The panel production process is intended to improve the quality and reliability of the different production phases and the structural performance of the panels. Thermal insulation provided by the panel elements reduces energy consumption by half, as can the contaminating emissions produced by heating and air-conditioning in buildings. Building with panels means producing dwellings with greater and better use of energy and, consequently, energy savings of up to 80% over the lifetime of the building. The panels bring a notable improvement in thermal comfort inside buildings, in particular limiting consumption of energy and favoring strategies for sustainable development. Throughout the lifetime of the building, the excellent insulating qualities of the panel elements ensure low energy consumption and reduced CO2 emissions, thereby contributing to limiting climate change and global warming. In a comparative analysis on CO2 production between an integrated construction system with individual panels and a traditional system, the construction of a building with the panel elements reduces CO2 production by almost 60% compared to a traditional building constructed with reinforced concrete girders and pillars and clad with an insulating wall.

Expandable polystyrene (EPS), which can be a component of the panel elements, has been classified and certified by the most prominent approval organizations as a completely eco-compatible material with low environmental impact. It does not give off toxic or harmful substances and is totally inert. It does not contain chlorofluorocarbons (CFC) or hydrochlorofluorocarbons (HCFC). Furthermore, as it contains no organic material, it inhibits the growth of micro-organisms and mold. Its mechanical and thermal characteristics are guaranteed for the full lifetime of the building, depending on the region where it is built. It does not suffer permanent damage if it is exposed to vapor or humidity. Any EPS waste there may be is directly recycled in the same production plant. It is not toxic. It does not harm the health of anyone producing or installing it.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a framework formed by a plurality of connected bent steel structural profiles for supporting an arrangement of modules for a building constructed according to the present invention.

FIG. 2 is a perspective view of a plurality of bent steel structural profiles for supporting staircase modules for a building constructed according to the present invention.

FIG. 3 is a perspective view of a partial house module arrangement constructed according to the present invention.

FIGS. 4a and 4b are exploded views of a building constructed in accordance with the present invention utilizing boxes, staircase modules and bridges.

FIG. 5 is a broken perspective view of an elongate structural bent steel profile according to the present invention.

FIG. 6 is an end view of the elongate structural bent steel profile shown in FIG. 5.

DETAILED DESCRIPTION OF THE INVENTION

The construction system according to the present invention can be considered to be a “kit” formed of a set of elements that, when assembled, produce the desired architectural result (the building), the elements including the metal structure and the composite panels with a hollow core. They are quantified depending on the function of the typology in which the construction system is used. Elements of the metal structure can include bolt plates, tie bolts, columns, long girders, short girders, connection nodes, connection bolts and reinforcement plates. Elements of composite panels with hollow core can include composite panels with hollow slab core (sheet), composite panels with hollow core for exterior vertical walls, and composite panels with hollow core for interior vertical walls.

The construction system of the present invention typically includes building modules and staircase modules, both made up of the aforementioned kit elements. The modules are stacked in a metal framework 40 to form resistant tubular modules as shown in FIG. 1, where the stacked modules are supported by a plurality of cold-shaped elongate profiles P creating the framework 40. The profiles are formed of steel coil, for example, A715-92° steel which covers high-resistance and low-alloy sheets and strips and cold-laminated sheets with improved shaping properties compared to A606 and A607. Profiles 42 act as horizontal girders and profiles 44 act as vertical columns. The profiles are supplied in cut lengths or in reels to form elongate structural elements available in four resistance levels, 50°, 60°, 70° and 80°; and eight types (according to chemical composition). The steel is transformed into a fine, granular material and includes elements of microaeleation, such as columbium, vanadium, titanium and zirconium, etc.

As shown in FIGS. 2 and 3, respectively, the modules can be staircase modules and house or office modules with roof panels 52 formed at the top of the resulting building. Other types of steel of less resistance can be used with the structural calculations, and thus the dimensions of the profiles and the resistant tubular modules can be adapted to the desired requirements, (e.g. earthquakes, tornadoes and the like).

The construction system process includes the steps of laying out a foundation on slabs, with boards and tie bolts, positioning and securing of profile columns, assembling the framework of the slabs (the slabs can be put together on the ground before being hoisted up), hoisting the assembled slabs up and fixing with connecting bolts, securing connections, positioning subfloor panels, positioning roof slab panels, and positioning partition and wall panels.

Some of the advantages of the construction system of the present invention compared to prior art modular systems are that prior art modules have a disadvantage which has laid them open to criticism from architects and users, namely their extreme rigidity for the arrangement of the spaces. Indeed, the dimensions of the prior art modules are limited by the maximum weight that can be lifted by the respective equipment. Furthermore, there are maximum dimensions which must be complied with for handling and erecting prefabricated modules. For this reason, when it is necessary to obtain larger spaces allowing greater flexibility in architectural organization, existing module building systems cannot be used. This disadvantage has been overcome by the construction system of the present invention because the areas formed with the prefabricated modules are selected among those in which the rigidity imposed by the module presents no difficulty for the architectural design but which, on the contrary, improves this design from the construction point of view. Such is the case for the kitchen and bathroom areas, which can be put together on the ground in one assembly line, with all utilities, including fixtures and fittings. The spaces which require greater flexibility are put in the bridge, made up of the prefabricated floor which is supported by the resistant tubular modules. This space is limited in two directions by the walls of the modules and, in the other four directions, by modules and bridges, prefabricated panels, either walls or floors. The possibilities for combining modules and bridges are infinite and allow the architect to display all his/her imagination and creativity in order to achieve better shapes and spatial systems. Furthermore, the possibility of varying the separation between the resistant tubular module groupings within the same building or group of buildings breaks with the monotony of buildings using existing prefabricated module systems. The use of prefabricated panels on façades allows for variations in shapes and textures, giving a richer overall effect.

A fundamental element in the structure of a building being built with the construction system of the present invention is the resistant tubular module. This module is formed by the vertical stacking of the individual modules and the joining of the integrated structural elements within those modules using various connecting systems, the most important of which, in the case of high-rise buildings, is the use of post-tension cables or bars which, through compression on the columns, slabs or screens, forms a structural unit able to withstand the static or dynamic pressures of axial or horizontal forces. The use of post-tension elements allows for savings in the implementation of the system, because it eliminates weight in the components, which is an advantage as regards handling the prefabricated components, as well as regarding the reduction in seismic forces on the structure. In buildings of more than fifteen floors, horizontal forces can be resisted by way of the girders connecting the resistant tubular modules such that the building will react as a whole to seismic forces or wind. In the case of low-rise buildings, the vertical connection elements (columns) act as poles which, in combination with the connection nodes, can be used to hoist up the slabs that have been previously reinforced on the ground. The construction system combines metal structural elements with lightweight composite panels, which increases the rigidity and resistance of the resistant tubular modules and makes a continuous slab on the bridges.

The construction system has the following advantages: it reduces the number of heavy units which have to be erected in a building; it allows for the mounting of utilities and fittings to be concentrated in only one part of the group of prefabricated units (modules designed for utilities); the greater part of the constructed prefabricated area can be built with lightweight equipment, representing a saving on building costs; alternatives can be used as regards the type of interior partitions in the flexible areas, making use of the system feasible in buildings of greater quality and comfort; production of the majority of the building elements can be industrialized; and the use of lightweight composite panels means that the steel structure, subfloor slab and external and internal composite walls can be assembled in one single step.

Based conceptually on a reasonable flexibility of spaces, concentration and differentiation of damp elements and/or areas with dry elements and/or invariant and variant spaces, the construction system permits easy and quick assembly with a construction process that does not require specializations. As a principle, the construction system poses the differentiation between “type” and “typology.” The concept of type refers to a sort of characteristic concentrated in the buildings, where the aim is to reproduce a standard model or archetype, attempting to reproduce a single characteristic of the variables presented. It supposes a reduction in the variation. This concept, by not considering other factors, for example environmental factors, results in the design of a dwelling which, by way of its homogenous characteristics leads to the establishment of models which repeat themselves according to cost savings. The scale of the buildings depends on the sum of requirements, with the human scale being lost. The concept of typology comes from the explanation of the formal and temporal variables which take into account not only the economic factor, but also include the alternatives which arise in a geographical context in a determined time, also considering the cultural aspect, which consists of a set of cultural, emotional and mnemonic assessments, for which the block of elements constituting the building appear as a unitary model, preferable to other, similar models (prototypes or derivatives), or including the specific effective and cultural attributes of a way of life. Approaching the architectural design process from this point of view allows for the variants and invariants, which are the product of the recognition of cultural and environmental determinants, to be considered. The construction system tends to establish typologies.

The basic elements of the construction system of the present invention include the metal framework 40 as shown in FIG. 1, the staircase modules shown in FIG. 2 and the home/office modules shown in FIG. 3 which are formed in the metal framework 40 and create structural modules as shown in FIGS. 4a and 4b . The structural modules feature an open (top and bottom) horizontal box 62, constructed of a system of panels 64 made of normal and/or hollow-core concrete, metals, resins, or combinations of any of these. Joints are fixed with bolts or welding and slabs 66 which form the bottom or top can be solid or ribbed and may have areas filled with lightweight material allowing for utilities to be embedded and limiting the weight to a minimum. The stacked arrangement of the modules creates resistant tubular modules, which bear the horizontal and vertical load requirements of the building. The use of elements such as brackets, bolts or other devices serving to support or join other horizontal structural elements, such as hollow-core girders and slabs, which connect the resistant tubular modules in the form of a bridge 70, creating a large frame that offers greater resistance to seismic pressures and can be used in conjunction with the system of panels, whether in normal or hollow-core reinforced concrete, metal, resins or a combination of any of these. Each module can form part of a specific unit of a dwelling. All elements for the final touches, finishing and utilities can be incorporated before the modules are erected on the same production line. With the construction system of the present invention, the resistant tubular modules can be laid out on the ground plan according to any model drawn up in the design (e.g. linear, bi-linear and radial). The construction system allows for the design of a module which, because of its laminar structure, can be moved from the vertical stack in the direction of its greatest dimension, thereby obtaining a building which is staggered on one side and flies on the other. Constructively, the modules can be prefabricated in a factory or elsewhere or be put together on an ongoing basis, and the lightweight composite panels allow the steel structure, subfloor slab and external and internal composite walls to be assembled in one single step.

As noted, the construction system is characterized by a metal framework, structure system which forms one or more resistant tubular modules, combining boxes and bridges, jointly using panels which can be made of normal or hollow-core concrete, metals or resins, or combinations of any of these types, to erect multiple-floor buildings which can serve as dwellings, offices, hotels or other services. The modules are positioned so that, when stacked one on top of another, the upper and lower spaces formed have a common element. The walls of the modules can be of uniform or variable thickness, depending on the structural resistance requirements corresponding to each building. The use of embedded elements such as brackets, steel bolts and other devices serve as supports or joints. The use of hollow-core slabs as top and bottom elements gives greater structural rigidity and enables sanitary and mechanical utilities to be embedded in them, limiting weight to a minimum. The lightened elements can be ribbed slabs with or without filling, hollow-core slabs or the like. The resistant tubular modules take all the horizontal and vertical load requirements of the building. The resistant tubular modules are formed by the vertical stacking of the modules fixed together with joints, which can have cement mortars, synthetic resins or Neoprene as interface materials and can be fixed with steel clamps and bolts. To achieve better structural unity and eliminate tensile stress, a system of post-tension cables or bars can be put in place from top to bottom, throughout the walls of the stacked prefabricated modules or of the columns embedded in rows. A building thus formed, is held together monolithically by the effects of post-tension. The structure is designed to take all the vertical and horizontal loads bearing on it and is, therefore, called a resistant tubular module. More complete structures can be formed with the use of girder structural elements which connect the resistant tubular modules, forming a large frame which gives greater resistance to seismic pressures on the building.

The absence of a limit in the separation between the resistant tubular modules permits separation from 2 m to 15 m or more, naturally depending on the thicknesses which are to be given to the slabs forming part of the bridge connecting them. This is achieved with the use of ribbed hollow-core slabs, with or without filling, as bridging elements between the resistant tubular modules by which they are supported. The ribbed slabs form a monolithic unit with the top or bottom of the individual module, with the use of mortar between the joints and longitudinal and transversal post-tension.

The use of special prefabricated modules for areas with complex finishes, such as bathrooms and kitchens, are manufactured on the assembly line on the ground so that, before they are erected on the level that they occupy in the building, they already contain all the utilities, fixtures, windows, doors and fittings. The use of lightweight composite panels allows the steel structure, the subfloor slab and the external and internal composite walls to be assembled in one single step.

Some of the advantages of the panel elements used in the construction system include thermal insulation due to the panels responding perfectly to both load-bearing and insulating functions. The thickness and density of the panels are designed according to a specific thermal insulation that has been selected. The EPS base spreads without breaks across all the surfaces constituting the envelope of the building, without any thermal bridges, (e.g., a panel element with a finished thickness of almost 15 cm has a thermal insulation similar to that of an insulated masonry wall of some 40 cm, which leads to obvious advantages of larger usable spaces). Combination with sound-absorbing materials, such as plasterboard, cork, coco fiber, mineral wool and the like, optimizes the insulation of walls to comply with the most restrictive acoustic regulations. Resistance to weight in many laboratory tests carried out in different parts of the world have highlighted the panel elements' high resistance to weight. For example, compression tests, with a weight in the center, carried out on a standard finished panel 270 cm in height, obtained a maximum ultimate load equal to 1530 kN/m. Resistance to fire results from the quality of the expanded polystyrene used in the panel elements which is self-extinguishing and two concrete layers covering the sides of the panel prevent combustion. A wall built with the panel elements has demonstrated resistance to fire of above RE1120. Resistance to explosions in the panel elements covered with different types of high-resistance concrete produces an even shockwave on the front of the panels. The panels are lightweight and, at the same time, sufficiently rigid even before finishing with shotcrete, making them easy to handle and mount, including in difficult working conditions. A consistent reduction in construction times for building in comparison to those built with traditional systems. Walls built with the panels can be finished by applying a thick covering directly to the rough plaster or, alternatively, traditional paints on smoothed plaster allowing the use of any type of covering. Accordingly, the panels are advantageous both for the end user and for companies, because they provide better performance compared to traditional products at much lower costs.

Composite panel elements with hollow cores can be used on one or more floors. The composite panels can form hollow slab cores (sheets), exterior vertical walls or interior vertical walls.

The elongate structural profile P according to the present invention, is shown in FIGS. 5 and 6. The profile P is made of bendable steel as described above having a length L with opposing ends 82 and 84 with a uniform shape in cross-section along the length L between the opposing ends. The shape defines a central web 86 having a first longitudinal edge 88 and a second longitudinal edge 90 defining a width W therebetween, a planar side flange 92 extending from longitudinal edge 88 to be perpendicular to web 86, a planar side flange 94 extending from longitudinal edge 90 to be perpendicular to web 88 and in spaced parallel relation to side flange 92, a “V” shaped indentation 96 in the web 86 running centrally the length of the profile, a stiffening planar inner flange 98 extending from side flange 92 toward indentation 96 and a stiffening planar inner flange 100 extending from side flange 94 toward indentation 96 such that the stiffening inner flanges 98 and 100 are disposed in a plane parallel to and spaced from web 86. The stiffening inner flanges 98 and 100 terminate at inner edges 102 and 104, respectively, that are spaced from each other. The stiffening inner flanges strengthen the side flanges to prevent local buckling in that the stiffening reinforces the profile to allow the profile to be calculated as a closed element while reducing weight. The length “S₁+S₂” of the stiffening created by the inner flanges is at least one-third of the width W of the web 86. The indentation 96 forms a reinforcing rib, and similar reinforcing indentations (ribs) can be disposed at various positions and in various numbers on the flanges.

As shown in FIG. 6, the shape of the profile P allows, in addition to resistance, for inserting walls in the concavity between edges 102 and 104, whether blocks or panels, creating a ‘mechanical seal’ and thus avoiding the cracks that are produced when different kinds of materials are joined.

Inasmuch as the present invention is subject to many variations, modifications and changes in detail, it is intended that all subject matter discussed above or shown in the accompanying drawings be interpreted as illustrative only and not be taken in a limiting sense. 

What is claimed is:
 1. A construction system for multi-level buildings comprising a plurality of modules stacked one on top of the other, each of said modules having vertical side walls such that said stacked modules create tubular resistant modules forming spaced hollow columns; a bridge flexibly connected with said hollow columns; and a plurality of elongate structural profiles used as column and beam components in said modules, each of said profiles having first and second opposing ends, each of said profiles being made of bendable steel bent to have uniform cross-sections along the length thereof between said first and second ends, said cross sections defining a web having first and second longitudinal side edges defining a width therebetween, first and second spaced, planar side flanges extending from said first and second side edges of said web, respectively, to be perpendicular to said web from said first end to said second end of said profile, an indentation in said web having a “V” shape, and first and second planar stiffening inner flanges extending toward said indentation from said first and second planar side flanges, respectively, said stiffening inner flanges being disposed in a plane parallel to and spaced from said web and terminating at inner edges spaced from each other.
 2. A construction system as recited in claim 1 wherein said plurality of profiles are joined together to form rigid frames pre-assembled at a factory for transportation to a construction site for the buildings and said modules are formed using said profiles as columns and beams.
 3. A construction system as recited in claim 2 wherein said modules are open boxes formed of panels coupled with said columns and beams forming said metal frames
 4. A construction system as recited in claim 3 wherein said boxes are grouped to accommodate damp elements.
 5. A construction system as recited in claim 3 wherein said modules are grouped to form building modules and staircase modules.
 6. An elongate steel structural profile for use as a column or beam building element in construction of a building, said profile being made of bendable steel bent to have a uniform cross-section along the length thereof between said first and second ends, said cross section defining a web having first and second longitudinal side edges defining a width therebetween, first and second spaced, planar side flanges extending from said first and second side edges of said web, respectively, to be perpendicular to said web from said first end to said second end of said profile, an indentation in said web having a “V” shape, and first and second planar stiffening inner flanges extending toward said indentation from said first and second planar side flanges, respectively, said stiffening inner flanges being disposed in a plane parallel to said web and terminating at inner edges spaced from each other. 